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post #1 of 16 Old 01-28-2011, 01:59 PM Thread Starter
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Help: Sporadic Gauges

I just picked my bike up from the local dealership. They replaced the clutch discs and springs. All is well there now. However, I picked it up with a new problem. The full gauge cluster is acting wacky. All of the gauges (clock, fuel, temp, speedo, rpm and odometer) work intermittently. I immediately pointed it out to the mechanics upon pick up. We fussed with it and it seems that the ECU or a wire at the ECU is the culprit.

Here is my question: what could have caused this and is it a coincidence in timing or was it something that the shop did?

Here’s what I gathered. The mechanic took it out for a test ride after working on the clutch and says that the gauges worked at the time. They then washed the bike with a pressure washer and it had the issue when I picked it up shortly thereafter. The bottom of the ECU was wet upon my inspection. It looks like he sprayed up under the seat from the engine area. We used the compressor to blow air in the connectors. I have the bike at home now and hope that time will dry out the issue. When I get home tonight I’ll see if that does the trick. Any other suggestions as to what I should do? If they got water in the connections, could that cause the ECU to fail?

I’ll keep you informed on how this turns out. Any suggestions are appreciated.

Edit: It appears that the harness has a few wires that rubbed through. The dealership has been very helpful in finding the issue... of course I wish that this was free, but the nature of business is to make money. In hind sight I should not have mentioned anything about blame before knowing the actual problem.

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2012 DL 650
1991 DR350S (dirty bike)
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Last edited by WeeMcD; 02-01-2011 at 03:25 PM. Reason: Updated information
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post #2 of 16 Old 01-28-2011, 02:13 PM
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It's likely a marginal connection and shouldn't cause ECU harm. When everything dries out, it will probably be fine. It's funny how so many problem reports start out with, "I just washed my bike". The marginal connection can be anywhere between the ECU and the gauge cluster. There are a few of them.

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post #3 of 16 Old 01-28-2011, 03:16 PM Thread Starter
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Thanks for the reassurance GW. I'll post up when I get home and check it out again. Hopefully, the problem simply evaporates with the moisture.

2007 DL 650 SOLD with 56k miles
2012 DL 650
1991 DR350S (dirty bike)
2004 DR 200 (wife's dirty bike)

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post #4 of 16 Old 01-28-2011, 03:25 PM
 
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A pressure washer? Jesus, no wonder it's having problems.


Couldn't they see it's a fairingless motorcycle, not a concrete sidewalk or a shake roof?
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post #5 of 16 Old 01-29-2011, 03:29 PM Thread Starter
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Time hasn't cured the electrical ills. Back to the shop it goes.

2007 DL 650 SOLD with 56k miles
2012 DL 650
1991 DR350S (dirty bike)
2004 DR 200 (wife's dirty bike)

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post #6 of 16 Old 01-30-2011, 03:45 PM Thread Starter
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Well, the shop sent me this picture. It is blurry, but I think it shows the reason why the guages are funky. It appears that the wires running on the left side of the bike under the tank have been rubbing.

What would be the best fix? Perhaps cut the affected wires, twist in new wire heat shrink it back together and call it good? Shop quated me $400 for the work. Seems that I could do it with a few bucks and labor.

This seems to be proof that coincidences do happen. The mechanic and washer had nothing to do with the problem as far as I can tell.


2007 DL 650 SOLD with 56k miles
2012 DL 650
1991 DR350S (dirty bike)
2004 DR 200 (wife's dirty bike)

Janitor, writer and editor of BestScenicRoutes.com. Explore It. Experience It.

Real name: Sean McDermott

Last edited by Black Lab; 01-30-2011 at 04:39 PM.
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post #7 of 16 Old 01-30-2011, 03:53 PM
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Why $400? Are they just looking to bend you over or is there more of a repair than meets the eye? The picture says you need two inches of new wire, butt connectors and electrical tape making it a .75 cent fix.

-ZR
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post #8 of 16 Old 01-30-2011, 04:41 PM
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Quote:
Originally Posted by WeeMcD View Post
What would be the best fix?
If I were making this repair, I would snip the chaffed wire, slide a piece of heat shrink tubing over one end, (and far enough away from the repair area.), solder the two ends back together, slide the heat shrink tubing over the soldered area, apply heat to that, and call it good.

B.L.

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post #9 of 16 Old 01-30-2011, 04:46 PM
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I imagine the dealer wants to replace the wiring harness.

Sean- I had a similar problem last summer and just did the splice and shrink wrap. Worked great. Put some extra covering (Available at most auto parts.) on it to prevent future problems.

Don

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Last edited by nvr2old; 01-30-2011 at 11:28 PM.
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post #10 of 16 Old 01-30-2011, 05:05 PM
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The liquid electical tape works wonders too. It will seal moisture out better than tape or shrink wrap.

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